Download Argo AWR222CLE - AER222SC Service manual

TECHNICAL & SERVICE MANUAL
AWR222CLE - AER222SC
AWR222CLE - AER222SC3
SPLIT SYSTEM AIR CONDITIONER
0.8180.076.0
03/00
When Transporting
Important!
Please Read Before Starting
Be careful when picking up and moving the indoor and
outdoor units. Get a partner to help, and bend your
knees when lifting to reduce strain on your back. Sharp
edges or thin aluminum fins on the air conditioner can
cut your fingers.
This air conditioning system meets strict safety and
operating standards. As the installer or service person,
it is an important part of your job to install or service the
system so it operates safely and efficiently.
When Installing…
For safe installation and trouble-free operation, you
must:
…In a Ceiling or Wall
Make sure the ceiling/wall is strong enough to hold the
units weight. It may be necessary to construct a strong
wood or metal frame to provide added support.
● Carefully read this instruction booklet before
beginning.
● Follow each installation or repair step exactly as
shown.
…In a Room
Properly insulate any tubing run inside a room to
prevent “sweating” that can cause dripping and water
damage to walls and floors.
● Observe all local, state, and national electrical codes.
● Pay close attention to all warning and caution notices
given in this manual.
WARNING
CAUTION
…In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to
provide a solid, level foundation for the outdoor unit.
This prevents water damage and abnormal vibration.
This symbol refers to a hazard or
unsafe practice which can result
in severe personal injury or
death.
…In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.
This symbol refers to a hazard or
unsafe practice which can result
in personal injury or product or
property damage.
…In a Snowy Area (for Heat Pump-type Systems)
Install the outdoor unit on a raised platform that is
higher than drifting snow. Provide snow vents.
If Necessary, Get Help
When Connecting Refrigerant Tubing
These instructions are all you need for most installation
sites and maintenance conditions. If you require help
for a special problem, contact our sales/service outlet
or your certified dealer for additional instructions.
• Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces
of the flare and union tubes before connecting them,
then tighten the nut with a torque wrench for a leakfree connection.
In Case of Improper Installation
The manufacturer shall in no way be responsible for
improper installation or maintenance service, including
failure to follow the instructions in this document.
• Check carefully for leaks before starting the test run.
When Servicing
• Turn the power off at the main power box (mains)
before opening the unit to check or repair electrical
parts and wiring.
Special Precautions
WARNING
When Wiring
• Keep your fingers and clothing away from any
moving parts.
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR
DEATH. ONLY A QUALIFIED,
EXPERIENCED ELECTRICIAN SHOULD
ATTEMPT TO WIRE THIS SYSTEM.
• Clean up the site after you finish, remembering to
check that no metal scraps or bits of wiring have
been left inside the unit being serviced.
Others
• Do not supply power to the unit until all wiring and
tubing are completed or reconnected and checked.
CAUTION
• Highly dangerous electrical voltages are used in this
system. Carefully refer to the wiring diagram and
these instructions when wiring. Improper connections
and inadequate grounding can cause accidental
injury or death.
• Ventilate any enclosed areas when installing or
testing the refrigeration system. Escaped refrigerant
gas, on contact with fire or heat, can produce
dangerously toxic gas.
• Confirm upon completing installation that no
refrigerant gas is leaking. If escaped gas comes in
contact with a stove, gas water heater, electric room
heater or other heat source, it can produce
dangerously toxic gas.
• Ground the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause
overheating at connection points and a possible fire
hazard.
i
Table of Contents
Page
1. OPERATING RANGE .............................................................................................................................. 1
2. SPECIFICATIONS
2-1. Unit Specifications .......................................................................................................................... 2
2-2. Major Component Specifications.................................................................................................... 4
2-3. Other Component Specifications.................................................................................................... 7
3. DIMENSIONAL DATA.............................................................................................................................. 8
4. REFRIGERANT FLOW DIAGRAM ......................................................................................................... 10
5. PERFORMANCE DATA
5-1. Performance charts ....................................................................................................................... 11
5-2. Air Throw Distance Chart .............................................................................................................. 13
5-3. Cooling Capacity ........................................................................................................................... 14
6. ELECTRICAL DATA
6-1. Electrical Characteristics ................................................................................................................ 16
6-2. Electric Wiring Diagrams ................................................................................................................ 17
7. FUNCTION
7-1. Room Temperature Control ........................................................................................................... 20
7-2. Freeze Prevention ......................................................................................................................... 21
7-3. Outdoor Fan Speed Control .......................................................................................................... 22
8. TROUBLESHOOTING
8-1. Check before and after troubleshooting ........................................................................................ 23
8-2. Air conditioner does not operate .................................................................................................... 24
8-3. Some part of air conditioner does not operate .............................................................................. 30
8-4. Air conditioner operates, but abnormalities are observed ............................................................. 32
8-5. If a sensor is defective ................................................................................................................... 33
9. REFRIGERANT R407C: SPECIAL PRECAUTIONS WHEN SERVICING THE UNIT
9-1. Characteristics of new refrigerant R407C.......................................................................................
9-2. Checklist before serving .................................................................................................................
9-3. Tools specifically for R407C ...........................................................................................................
9-4. For tubing installation procedures ..................................................................................................
9-5. In case of compressor malfunction.................................................................................................
9-6. In case refrigerant is leaking...........................................................................................................
9-7. Charging additional refrigerant .......................................................................................................
9-8. Retro-fitting existing systems..........................................................................................................
34
34
35
35
36
38
40
40
11. CHECKING ELECTRICAL COMPONENTS
11-1. Measurement of Insulation Resistance .......................................................................................... 45
11-2. Checking Continuity of Fuse on PCB Ass'y.................................................................................... 46
11-3. Checking Motor Capacitor ............................................................................................................. 46
APPENDIX INSTRUCTION MANUAL ........................................................................................................ 47
ii
1. OPERATING RANGE
Temperature
Cooling
Indoor Air Intake Temp.
Outdoor Air Intake Temp.
Maximum
32°C D.B. / 23°C W.B.
43°C D.B.
Minimum
19°C D.B. / 14°C W.B.
19°C D.B.
1
2. SPECIFICATIONS
2-1. Unit Specifications
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC
Electrical Rating
Performance
Power Source
220 – 240 V ~ 50 Hz
Cooling
kW
Capacity
6.35 / 6.40 / 6.40
BTU/h
Air circulation (High)
Moisture removal (High)
21,669 / 21,837 / 21,840
m3/h
900
Liters/h
3.3
Voltage rating
V
220 / 230 / 240
Available voltage range
V
198 to 264
Running amperes
A
13.1 / 13.0 / 13.0
Power input
W
2,850 / 2,900 / 2,950
Power factor
%
C.O.P.
99 / 97 / 95
W/W
Compressor locked rotor amperes
2.2 / 2.2 / 2.2
A
67 / 70 / 73
Controls / Temperature control
Microprocessor / I.C. thermostat
Control unit
Wireless remote control unit
Timer
ON/OFF 24-hours & Daily Program
Fan speeds
Indoor / Outdoor
Airflow direction (Indoor )
3 and Auto / 2 (Auto)
Horizontal
Manual
Vertical
Auto
Features
Air filter
Washable, Anti-Mold
Compressor
Rotary (Hermetic)
Refrigerant / Amount charged at shipment
g
R407C / 2,620
Refrigerant control
Operation sound
Capillary tube
Indoor – Hi / Me / Lo
dB-A
Outdoor – Hi
dB-A
47 / 44 / 40
55
Refrigerant tubing connections
Max. allowable tubing length at shipment
Refrigerant tube
diameter
Flare type
m
Narrow tube
mm (in.)
Wide tube
mm (in.)
10
6.35 (1/4)
15.88 (5/8)
Refrigerant tube kit / Accessories
Dimensions & Weight
Unit dimensions
Package dimensions
Weight
Shipping volume
Optional / Hanging wall bracket
Indoor Unit
Outdoor Unit
mm
360
835
Width
mm
1,000
850
Depth
mm
205
305
Height
Height
mm
282
913
Width
mm
1,080
1,000
Depth
mm
443
400
kg
13.5
67.0
Net
Shipping
kg
17.7
76.0
m3
0.13
0.37
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks: Rating conditions are:
Indoor air temperature 27°C DB/19°C WB
Outdoor air temperature 35°C DB/24°C WB
2
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC3
380 – 400 V – 3N ~ 50 Hz
220 – 240 V ~ 50 Hz
Electrical Rating
Performance
Power Source
Control Circuit
Cooling
kW
Capacity
6.25
BTU/h
21,325
m3/h
Air circulation (High)
Moisture removal (High)
900
Liters/h
3.3
Voltage rating
V
380 / 400
Available voltage range
V
342 to 440
Running amperes
A
4.5
Power input
W
2,750
Power factor
%
—
W/W
2.3
A
28
C.O.P.
Compressor locked rotor amperes
Controls / Temperature control
Microprocessor / I.C. thermostat
Control unit
Wireless remote control unit
Timer
ON/OFF 24-hours & Daily Program
Fan speeds
Indoor / Outdoor
Airflow direction (Indoor )
3 and Auto / 2 (Auto)
Horizontal
Manual
Vertical
Auto
Features
Air filter
Washable, Anti-Mold
Compressor
Rotary (Hermetic)
Refrigerant / Amount charged at shipment
g
R407C / 2,510
Refrigerant control
Operation sound
Capillary tube
Indoor – Hi / Me / Lo
dB-A
48 / 45 / 41
Outdoor – Hi
dB-A
55
Refrigerant tubing connections
Max. allowable tubing length at shipment
Refrigerant tube
diameter
Flare type
m
10
Narrow tube
mm (in.)
6.35 (1/4)
Wide tube
mm (in.)
15.88 (5/8)
Refrigerant tube kit / Accessories
Optional / Hanging wall bracket
Indoor Unit
Dimensions & Weight
Unit dimensions
Package dimensions
Weight
Shipping volume
Outdoor Unit
Height
mm
360
835
Width
mm
1,000
850
Depth
mm
205
305
Height
mm
282
913
Width
mm
1,080
1,000
Depth
mm
443
400
Net
Shipping
kg
13.5
67.0
kg
17.7
76.0
m3
0.13
0.37
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
Remarks: Rating conditions are:
Indoor air temperature 27°C DB/19°C WB
Outdoor air temperature 35°C DB/24°C WB
3
2-1. Major Component Specifications
2-2-1. Indoor Unit
Indoor Unit
AWR222CLE
Controller
PCB
Source
220 – 240 V ~ 50 Hz
Part No.
POW-K185GS-N
Controls
Microprocessor
Control circuit fuse
250 V – 3 A
Remote Control Unit
RCS - 2S1
Q´ty
Cross - flow
Number ... Dia. and length
mm
1 ... ø100 / L760
Fan motor model ... Q´ty
UF2T-31A5P-S ... 1
Fan & Fan Motor
No. of poles ... rpm (220 / 230 / 240 V, High)
W
Coil resistance (Ambient temp. 20°C)
Ω
WHT – BRN : 145.3
VLT – YEL : 30.9
YEL – PNK : 109.2
Type
Operating temp.
Internal type
Open
°C
130 ± 8
Close
Run capacitor
Louver Motor
30
WHT – VLT : 53.6
Safety
devices
Heat
Exch. Coil
2 ... 1,750 / 1,820 / 1,880
Nominal output
Automatic reclosing
µF
1.8
VAC
440
Model
M2LJ24ZE31
Rating
AC 230 V, 50 Hz
No. of poles ... rpm
Nominal output
Coil resistance (Ambient temp. 20°C)
8 ... 2.5
W
3
kΩ
16.45 ± 15%
Coil
Aluminum plate fin / Copper tube
Rows
Fin pitch
Face area
2
mm
1.8
m2
0.192
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
4
2-2-2. Outdoor Unit
Outdoor Unit
AER222SC
Type
Rotary (Hermetic)
Compressor model
C-RN221H5A 80244035
Source
220 – 240 V ~ 50 Hz
Nominal output
W
2,200
Compressor oil ... Amount
cc
FV68S ... 1,350
Coil resistance (Ambient temp. 25°C)
Ω
C – R : 0.777
Compressor
C – S : 2.408
Type
Safety
devices
Overload relay
Operating temp.
OL-D24
°C
Automatic opening
150 ± 5
Close
°C
Automatic reclosing
63 ± 10
—
µF
Run capacitor
Trip in 6 to 16 sec. at 59A
40.0
VAC
400
Crank case heater
240V 30W
Type
Propeller
Q´ty ... Dia.
mm
1 ... ø460
Fan motor model ... Q´ty
KFC6S-51B5P ... 1
220 – 240 V ~ 50 Hz
Source
Fan & Fan Motor
External protector (OLR)
—
Open
Operating amp.(Ambient temp. 25°C)
No. of poles ... rpm (220 V, High)
6 ... 860
Nominal output
W
Coil resistance (Ambient temp. 20°C)
Ω
50
WHT – BRN : 95.9
WHT – YEL : 55.4
YEL – PNK :
Safety
devices
Type
Operating temp.
Run capacitor
Heat
Exch. Coil
Internal protector
Open
°C
130 ± 8
Close
Automatic reclosing
µF
5.0
VAC
440
Coil
Aluminum plate fin / Copper tube
Rows
Fin pitch
Face area
7.2
Internal type
2
mm
1.9
m2
0.610
External Finish
Acrylic baked-on enamel finish
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
5
Outdoor Unit
AER222SC3
Power source
380 – 400 V – 3N ~ 50 Hz
Control circuit
220 – 240 V ~ 50 Hz
Type
Rotary (Hermetic)
Compressor model
C-RN223H8A 80244088
380 – 400 V – 3N ~ 50 Hz
Source
Nominal output
W
2,200
Compressor oil ... Amount
cc
FV68S ... 1,350
Coil resistance (Ambient temp. 25°C)
Ω
C – R : 4.97
Compressor
C – S : 4.64
R – S : 4.88
Type
Safety
devices
Overload relay
Operating temp.
HOE-10TB TH-7A
°C
Automatic opening
—
Close
°C
Automatic reclosing
—
—
µF
Run capacitor
7A
—
VAC
—
Crank case heater
240V 30W
Type
Propeller
Q´ty ... Dia.
mm
1 ... ø460
Fan motor model ... Q´ty
KFC6S-51B5P ... 1
220 – 230 V ~ 50 Hz
Source
No. of poles ... rpm (220 V, High)
Fan & Fan Motor
External protector
—
Open
Operating amp.(Ambient temp. 25°C)
6 ... 840
Nominal output
W
Coil resistance (Ambient temp. 20°C)
Ω
50
WHT – BRN : 95.9
WHT – PNK : 55.4
YEL – PNK :
Safety
devices
Type
Operating temp.
Run capacitor
Heat
Exch. Coil
Internal protector
Open
°C
130 ± 8
Close
Automatic reclosing
µF
5.0
VAC
440
Coil
Aluminum plate fin / Copper tube
Rows
Fin pitch
Face area
7.2
Internal type
2
mm
1.9
m2
0.610
External Finish
Acrylic baked-on enamel finish
DATA SUBJECT TO CHANGE WITHOUT NOTICE.
6
2-3. Other Component Specifications
Indoor Unit
AWR222CLE
Transformer (TR)
ATR-H85
Rating
Primary
AC 230V, 50/60Hz
Secondary
11V, 0.727A
Capacity
8VA
Ω (at 21°C)
Coil resistance
Primary (WHT – WHT):
214 ± 10%
Secondary (BRN – BRN):
1.58 ± 10%
Thermal cut-off temp.
145°C, 2A, 250V
Thermistor (Coil sensor TH1)
Resistance
PBC – 41E – S4
kΩ
– 20°C 40.1± 5%
20°C
6.5± 5%
– 10°C 24.4± 5%
30°C
4.4± 5%
0°C 15.3± 5%
40°C
3.0± 5%
50°C
2.1± 5%
10°C
Thermistor (Room sensor TH2)
Resistance
Outdoor Unit
KTEC-35-S6
kΩ
10°C 10.0 ± 4%
30°C 4.0 ± 4%
15°C
7.9 ± 4%
35°C 3.3 ± 4%
20°C
6.3 ± 4%
40°C 2.7 ± 4%
25°C
5.0 ± 4%
50°C 1.8 ± 4%
AER222SC
Magnetic Contactor (MG)
HE-20FT31B
Coil rating
AC 220/240V, 50Hz
Ω (at 25°C)
Coil resistance
1,050 ± 15%
Contact rating (Main)
AC 220V, 20A
Thermostat (Fan Speed Control 23S)
Switching temp.
Outdoor Unit
9.9± 5%
YTB-S383
°C
high → LOW
28.5°C ± 1
low → HIGH
31°C ± 1
AER222SC3
Electro Magnetic Contactor (MG)
HOE-10TB TH-7A
Magnetic Contactor
Coil rating
Coil resistance
AC 220–240V, 50Hz / AC 240–260V, 60Hz
Ω (at 25°C)
1,260 ± 10%
Contact rating (Main)
AC 440V, 8A
Thermal relay (Overcurrent relay)
Operating amperes
7A
Negative Phase Relay (47C)
RDR-S400
Rating
AC 415V, 3-phase 50Hz
Contact rating
AC 400V, 1A
Operation
Positive phase: ON
Negative phase: OFF
Thermostat (Fan Speed Control 23S)
Switching temp.
YTB-S383
°C
7
high → LOW
28.5°C ± 1
low → HIGH
31°C ± 1
3. DIMENSIONAL DATA
Indoor Unit
AWR222CLE
205
360
1000
Rear panel (center point of gravity)
172.5
Remote control unit
18.5
61
49
61
64
74
Drain hose ø26
Narrow tube ø6.35 (1/4")
Center of tubing hole
(for right rear)
Wide tube ø15.88 (5/8")
Unit : mm
8
Outdoor Unit
AER222SC
AER222SC3
Air intake
325
20
20
Air discharge
130
620
100
55
Wide tube service valve ø15.88 (5/8")
Narrow tube service valve ø6.35 (1/4")
6 – ø3.1 holes
285
86 73
229
57
835
560
250
Check port ø6.35 (1/4")
850
250
86
88
155
Unit : mm
9
4. REFRIGERANT FLOW DIAGRAM
Indoor Unit
AWR222CLE
Outdoor Unit
Indoor Unit
Outdoor Unit
Wide tube
Wide tube
service
valve
Muffler
Accumulator
O.D.
ø15.88 mm
(5/8 ")
Compressor
Condenser
Capillary for
liquid injection
Evaporator
Muffler
AER222SC
AER222SC3
Narrow tube
Narrow
tube
service
valve
O.D.
ø6.35 mm
(1/4")
Check port
Capillary tube
Drier
Insulation of Refrigerant Tubing
Insulation
IMPORTANT
Because capillary tubing is used in the outdoor unit, both the
wide and narrow tubes of this air conditioner become cold. To
prevent heat loss and wet floors due to dripping of
condensation, both tubes must be well insulated with a proper
insulation material. The thickness of the insulation should be a
min. 8 mm.
CAUTION
After a tube has been insulated,
never try to bend it into a narrow
curve because it can cause the tube
to break or crack.
10
Thickness:
Min. 8 mm
Thickness:
Min. 8 mm
Narrow tube
Wide tube
5. PERFORMANCE DATA
5-1. Performance charts
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC
■ Cooling Characteristics
Indoor inlet air
D.B. temp. (°C) 32
17
Outdoor
fan speed
Operating current (A)
16
15
Low
27
High
21
14
13
12
11
10
9
8
25
30
35
40
45
50
Low pressure at wide tube service valve
MPa (kgf/cm2G)
Outdoor inlet air D.B. temp. (°C)
Indoor inlet air
D.B. temp. (°C)
1.1 (10)
Outdoor
fan speed
1.0 ( 9 )
0.9 ( 8 )
Low
High
0.8 ( 7 )
0.7 ( 6 )
0.6 ( 5 )
0.5 ( 4 )
32
27
21
0.4 ( 3 )
0.3 ( 2 )
0.2 ( 1 )
0.1 ( 0 )
25
30
35
40
45
50
Outdoor inlet air D.B. temp. (°C)
NOTE
● ...... Points of Rating condition
Black dots in above charts indicate the following rating conditions.
Cooling: Indoor air temperature 27°C D.B./ 19°C W.B.
Outdoor air temperature 35°C D.B./24°C W.B.
11
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC3
■ Cooling Characteristics
Indoor inlet air
D.B. temp. (°C)
10
Outdoor
fan speed
Operating current (A)
9
8
Low
High
7
6
32
27
21
5
4
3
2
1
25
30
35
40
45
50
Low pressure at wide tube service valve
MPa (kgf/cm2G)
Outdoor inlet air D.B. temp. (°C)
Indoor inlet air
D.B. temp. (°C)
1.1 (10)
Outdoor
fan speed
1.0 ( 9 )
0.9 ( 8 )
Low
High
0.8 ( 7 )
0.7 ( 6 )
32
27
21
0.6 ( 5 )
0.5 ( 4 )
0.4 ( 3 )
0.3 ( 2 )
0.2 ( 1 )
0.1 ( 0 )
25
30
35
40
45
50
Outdoor inlet air D.B. temp. (°C)
NOTE
● ...... Points of Rating condition
Black dots in above charts indicate the following rating conditions.
Cooling: Indoor air temperature 27°C D.B./ 19°C W.B.
Outdoor air temperature 35°C D.B./24°C W.B.
12
5-2. Air Throw Distance Chart
AWR222CLE
Fan speed
:
High
Horizontal distance (m)
0
Axis air verocity (m/s)
Vertical distance (m)
Indoor Unit
1
2
3
4
5
6
1
2
3
4
Axis air verocity
Flap angle
13
0°
30°
7
8
9
5-3. Cooling Capacity
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC
240V Single Phase 50Hz
RATING CAPACITY
AIR FLOW RATE
EVAPORATOR
ENT. TEMP. °C
W.B.
D.B.
15
17
19
21
23
21
23
25
27
29
31
21
23
25
27
29
31
21
23
25
27
29
31
23
25
27
29
31
25
27
29
31
6.40 kW
900 m3/h
CONDENSER
OUTDOOR AMBIENT TEMP. °C
30
35
40
45
TC
5.89
5.61
5.27
4.85
CM
2.40
2.57
2.76
2.97
SHC
3.87
3.72
3.54
3.32
SHC
4.29
4.14
3.96
3.74
SHC
4.72
4.56
4.38
4.17
SHC
5.14
4.99
4.81
4.59
SHC
5.56
5.41
5.23
4.85
SHC
5.89
5.61
5.27
4.85
TC
6.32
6.02
5.66
5.20
CM
2.47
2.65
2.84
3.05
SHC
3.44
3.28
3.10
2.88
SHC
3.86
3.71
3.53
3.31
SHC
4.29
4.13
3.95
3.73
SHC
4.71
4.55
4.37
4.15
SHC
5.13
4.98
4.80
4.58
SHC
5.56
5.40
5.22
5.00
TC
6.72 # 6.40
6.02
5.54
CM
2.54
2.73
2.92
3.14
SHC
2.98
2.82
2.64
2.43
SHC
3.40
3.25
3.07
2.85
SHC
3.82
3.67
3.49
3.27
SHC
4.25
4.09
3.92
3.70
SHC
4.67
4.52
4.34
4.12
SHC
5.09
4.94
4.76
4.54
TC
7.12
6.78
6.38
5.87
CM
2.61
2.80
3.00
3.22
SHC
2.93
2.78
2.60
2.39
SHC
3.35
3.20
3.03
2.81
SHC
3.78
3.63
3.45
3.23
SHC
4.20
4.05
3.87
3.66
SHC
4.62
4.47
4.30
4.08
TC
7.55
7.12
6.67
6.20
CM
2.68
2.88
3.08
3.31
SHC
2.85
2.68
2.49
2.31
SHC
3.27
3.10
2.92
2.74
SHC
3.70
3.52
3.34
3.16
SHC
4.12
3.95
3.76
3.58
TC : Total Cooling Capacity (kW)
SHC : Sensible Heat Capacity (kW)
CM : Compressor Input (kW)
Rating conditions (#Mark) are
Outdoor Ambient Temp. 35°C D.B.
Indoor Unit Entering Air Temp. 27°C D.B. / 19°C W.B.
14
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC3
240V Single Phase 50Hz
RATING CAPACITY
AIR FLOW RATE
EVAPORATOR
ENT. TEMP. °C
W.B.
D.B.
15
17
19
21
23
21
23
25
27
29
31
21
23
25
27
29
31
21
23
25
27
29
31
23
25
27
29
31
25
27
29
31
6.25 kW
900 m3/h
CONDENSER
OUTDOOR AMBIENT TEMP. °C
30
35
40
45
TC
5.75
5.48
5.14
4.74
CM
2.25
2.41
2.63
2.92
SHC
3.80
3.65
3.48
3.27
SHC
4.22
4.08
3.90
3.69
SHC
4.65
4.50
4.32
4.11
SHC
5.07
4.92
4.75
4.54
SHC
5.49
5.35
5.14
4.74
SHC
5.75
5.48
5.14
4.74
TC
6.17
5.88
5.52
5.08
CM
2.31
2.48
2.70
2.99
SHC
3.37
3.22
3.04
2.83
SHC
3.79
3.64
3.47
3.26
SHC
4.22
4.07
3.89
3.68
SHC
4.64
4.49
4.32
4.10
SHC
5.06
4.91
4.74
4.53
SHC
5.49
5.34
5.16
4.95
TC
6.56 # 6.25
5.88
5.41
CM
2.38
2.56
2.79
3.08
SHC
2.91
2.76
2.59
2.38
SHC
3.33
3.18
3.01
2.80
SHC
3.75
3.61
3.43
3.22
SHC
4.18
4.03
3.86
3.65
SHC
4.60
4.45
4.28
4.07
SHC
5.03
4.88
4.70
4.49
TC
6.96
6.63
6.23
5.73
CM
2.45
2.63
2.86
3.16
SHC
2.86
2.72
2.55
2.34
SHC
3.29
3.14
2.97
2.76
SHC
3.71
3.56
3.39
3.19
SHC
4.13
3.99
3.82
3.61
SHC
4.56
4.41
4.24
4.03
TC
7.37
6.96
6.51
6.06
CM
2.51
2.70
2.94
3.24
SHC
2.78
2.62
2.44
2.27
SHC
3.21
3.04
2.86
2.69
SHC
3.63
3.46
3.29
3.11
SHC
4.05
3.89
3.71
3.54
TC : Total Cooling Capacity (kW)
SHC : Sensible Heat Capacity (kW)
CM : Compressor Input (kW)
Rating conditions (#Mark) are
Outdoor Ambient Temp. 35°C D.B.
Indoor Unit Entering Air Temp. 27°C D.B. / 19°C W.B.
15
6. ELECTRICAL DATA
6-1. Electrical Characteristics
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC
Indoor Unit
Outdoor Unit
Fan Motor
Fan Motor
Performance at
Rating Conditions
Complete Unit
Compressor
220 / 240V Single phase 50Hz
Running Amps.
Power Input
Full Load Conditions Running Amps.
Power Input
0.37
0.54 / 0.55
12.21 / 12.08
13.1 /
13.0
kW 0.077 / 0.089
A
0.116 / 0.134
2.657 / 2.727
2.85 /
2.95
0.37
0.54 / 0.55
15.21 / 15.18
16.1 /
16.1
kW 0.077 / 0.089
0.116 / 0.134
3.307 / 3.307
3.50 /
3.53
A
0.35 /
0.35 /
Rating Conditions
: Indoor Air Temperature 27°C D.B. / 19°C W.B.
Outdoor Air Temperature 35°C D.B.
Full Load Conditions : Indoor Air Temperature 32°C D.B. / 23°C W.B.
Outdoor Air Temperature 43°C D.B.
Indoor Unit
Outdoor Unit
AWR222CLE
AER222SC3
Indoor Unit
Outdoor Unit
Fan Motor
Performance at
Rating Conditions
Fan Motor
220V Single phase 50Hz
Running Amps.
Power Input
Full Load Conditions Running Amps.
Power Input
Complete Unit
Compressor
380V Three phase 50Hz
A
0.35
0.54
4.21
4.5
kW
0.077
0.116
2.557
2.75
A
0.35
0.54
5.31
5.6
kW
0.077
0.116
3.237
3.43
Rating Conditions
: Indoor Air Temperature 27°C D.B. / 19°C W.B.
Outdoor Air Temperature 35°C D.B.
Full Load Conditions : Indoor Air Temperature 32°C D.B. / 23°C W.B.
Outdoor Air Temperature 43°C D.B.
16
6-2. Electric Wiring Diagrams
Indoor Unit
AWR222CLE
WARNING
17
To avoid electrical shock hazard, be sure to
disconnect power before checking, servicing
and/or cleaning any electrical parts.
Outdoor Unit
AER222SC
WARNING
18
To avoid electrical shock hazard, be sure to
disconnect power before checking, servicing
and/or cleaning any electrical parts.
Outdoor Unit
AER222SC3
WARNING
19
To avoid electrical shock hazard, be sure to
disconnect power before checking, servicing
and/or cleaning any electrical parts.
7. FUNCTION
7-1. Room Temperature Control
● Room temperature control is obtained by cycling the compressor ON and OFF under control of the room
temperature sensor in the remote control unit.
● The room temperature (and other information) is transmitted every 3 minutes by the remote control unit to the
controller in the indoor unit.
Signal from remote control unit
3 minutes 3 minutes 3 minutes
Thermo.
OFF
set temp.
3 minutes
Thermo.
ON
Thermo.
OFF
3 minutes 3 minutes 3 minutes
Thermo.
ON
Thermo.
ON
Thermo.
ON
Thermo.
OFF
T+1 °C
T °C
More than
5 minutes
5 minutes
3 minutes
Room temp.
Compressor
ON
OFF
ON
OFF
ON
OFF
Outdoor fan
ON
OFF
ON
OFF
ON
OFF
Indoor fan
Set speed
● The control circuit will not attempt to turn the compressor ON until the compressor has been OFF for at least
3 minutes. To protect the compressor from stalling out when trying to start against the high side refrigerant
pressure, the control circuit has a built-in automatic time delay to allow the internal pressure to equalize.
● As a protective measure, the control circuit switches the compressor OFF after 5 minutes or more of compressor
operation.
● Thermo. ON : When the room temperature is above T + 1°C (T°C is set temperature).
Compressor ➞ ON
● Thermo. OFF : When the room temperature is equal to or below set temperature T°C.
Compressor ➞ OFF
20
7-2. Freeze Prevention
● This function prevents freezing of the indoor heat exchange coil.
● When the compressor has been running for 10 minutes or more and the temperature of the indoor heat
exchange coil falls below –1°C, the control circuit stops the compressor for at least 6 minutes. The compressor
does not start again until the temperature rises above 8°C or 6 minutes has elapsed.
Thermo. OFF
Thermo. ON
Room temp.
T+1 °C
Set temp. T °C
Indoor heat exch.
coil temp.
More than
6 minutes
6 minutes
–1 °C
More than
10 minutes
Compressor
Indoor fan
ON
More than
10 minutes
OFF
ON
Set speed
ON
OFF
Set speed
21
ON
7-3. Outdoor Fan Speed Control
● To optimize performance of the air conditioner, the outdoor fan speed is switched automatically according to the
outdoor temperature.
● If the outdoor air temperature falls below 28.5°C, the fan speed switches to LOW.
● If the outdoor air temperature rises above 31.0°C for 5minutes or longer, the fan speed switches to HIGH.
31
Outdoor air
temperature (°C)
28.5
Outdoor fan
speed
H
L
22
H
8. TROUBLESHOOTING
8-1. Check before and after troubleshooting
WARNING
Hazardous voltage can cause ELECTRIC SHOCK or
DEATH. Disconnect power or turn off circuit breaker
before you start checking or servicing.
8-1-1. Check power supply wiring.
● (For model AER222SC)
Check that power supply wires are correctly connected to terminals L and N on the terminal plate in the outdoor
unit.
● (For model AER222SC3)
Check that power supply wires are correctly connected to terminals L1,L2,L3 and N on the terminal plate in the
outdoor unit.
8-1-2. Check inter-unit wiring.
● Check that inter-unit wiring is correctly connected to the indoor unit from the outdoor unit.
Model: AER222SC
Outdoor
unit
Inter-unit
power wiring
1
2
Ground
4
Power supply:
220-240V~50Hz
Model: AER222SC3
Indoor
unit
Outdoor
unit
Indoor
unit
1
1
1
2
2
4
4
L
N
Ground
Power supply: L1
380 V – 400 V L2
3N ~ 50 Hz
L3
L1
N
N
Ground
L2
4
Inter-unit
wiring
L3
Ground
8-1-3. Check power supply.
● Check that voltage is in specified range (±10% of the rating).
● Check that power is being supplied.
8-1-4. Check lead wires and connectors in indoor and outdoor units.
● Check that coating of lead wires is not damaged.
● Check that lead wires and connectors are firmly connected.
● Check that wiring is correct.
23
2
8-2. Air conditioner does not operate.
8-2-1. Circuit breaker trips (or fuse blows).
A. When the circuit breaker is set to ON, it is tripped soon. (Resetting is not possible.)
●
There is a possibility of ground fault.
●
Check insulation resistance.
If resistance value is 2MΩ or less, insulation is defective (“NO”).
Model: AER222SC
1
Power
supply
wiring
L
N
Circuit
breaker
Power
supply
1
Inter-unit
wiring
Outdoor
unit
2
Indoor
unit
1
2
1
2
4
4
Ground
Model: AER222SC3
1
Power
supply
wiring
L1
Power L2
supply L3
1
Outdoor
unit
L1
2
Inter-unit
wiring
Indoor
unit
1
1
2
2
4
4
L2
L3
Circuit
breaker
N
N
Ground
WARNING
* Set circuit breaker to OFF.
1
Remove both power supply wires
and inter-unit wires from terminal
plate in outdoor unit.
• Measure insulation resistance
of outdoor unit.
Insulation of
outdoor unit
is defective.
NO
• Measure insulation
resistance of electrical
parts in outdoor unit.
2
Remove inter-unit wires from
terminal plate in indoor unit.
• Measure insulation resistance
of indoor unit.
Insulation of
indoor unit
is defective.
NO
• Measure insulation
resistance of electrical
parts in indoor unit.
24
B. Circuit breaker trips in several minutes after turning the air conditioner on.
● There is a possibility of short circuit.
• Check capacity of circuit breaker.
Replace with suitable
one (larger capacity).
NO
Capacity of circuit breaker is
suitable.
• Measure resistance of outdoor fan
motor winding.
• Measure resistance of compressor
motor winding.
25
8-2-2. Neither indoor nor outdoor unit runs.
A. Power is not supplied.
• Check power supply.
Circuit breaker
is tripped.
Reset breaker.
Power failure
Wait for recovery
or contact power
company.
NO
Power is being supplied to the
outdoor unit.
B. Check remote control unit.
• Try to run with another remote
control unit.
OK
First remote control unit is defective.
• Check for residue buildup on
transmitter of remote control unit.
Clean transmitter.
• Check for residue buildup on remote
control receiver on front of indoor
unit.
Clean receiver.
C. Check "OPERATION selector" switch in the indoor unit.
• OPERATION selector switch is set
in ON position.
YES
Switch Ass'y or indoor PCB Ass'y
is defective.
NO
Set OPERATION selector switch
to ON.
26
D. Check transformer in indoor unit.
• Measure resistance of primary and
secondary winding.
(TR1)
E. Check fuse on the indoor PCB Ass'y.
• Check fuse on indoor PCB Ass'y
for continuity.
(F)
If fuse has been blown,
• Measure resistance of indoor
fan motor winding.
(FMI)
OK
OK
• Measure resistance of louver
motor winding.
(LM)
• Check operation lamp to see
if light is ON.
Light is OFF
OK
• Measure resistance of primary and
secondary winding of transformer.
(TR)
• Measure coil resistance of magnetic
contactor
(MG)
OK
OK
• Check crank case heater
• Indoor PCB Ass'y or switch Ass'y
is defective.
(CH)
OK
• Replace the fuse.
F. Check TIMER SELECT button on the remote control unit.
• Timer is turned ON. Check to see
if ON
or
is displayed on
remote control
YES
Cancel the timer mode.
27
8-2-3. Only outdoor unit does not run.
A. Check setting temperature.
Is room temperature too low ?
NO
Try to lower setting temperature by
temperature setting button ( button).
Outdoor unit still does
not run.
• Try to run using another remote
control unit.
OK
Remote control unit is defective.
B. Check relay in outdoor unit. (AER222SC3)
• Measure coil resistance of relay.
(1X)
OK
Check indoor PCB Ass'y.
28
C. Check negative phase relay. (Only for 3-phase model)
• Check negative phase relay to see
if it has operated.
YES
• Rewire power supply wires.
D. Check magnetic contactor.
• Check coil resistance of magnetic
contactor.
(MG)
E. Check indoor PCB Ass'y.
F. Check compressor motor protector.
Temperature of compressor is
abnormally high.
• Check compressor motor
internal protector.
(49C)
YES
Outdoor heat exchanger coil
is dirty or there are obstacles
near air suction inlet.
NO
Refrigerant gas shortage.
YES
YES
• Clean heat exchanger or
remove obstacles.
Recover refrigerant. (R407C)
(Only for 3-phase model)
• Check compressor motor
overcurrent relay. (51C)
Evacuate the air conditioner.
It’s operated.
• Check power supply voltage.
Voltage is abnormally low.
CAUTION
Charge refrigerant in liquid
state.
(R407C)
NO 90% or more of
rated voltage.
• Check compressor.
There is a possibility of
locked rotor.
For compressor replacement
refer to "10-5. In case of
compressor malfunction".
29
In case of leakage, do not
add refrigerant. The unit
must be vacuumed and
recharged. This is because
composition of refrigerant
in the unit has been
changed due to leakage.
See "9-6. In case refrigerant
is leaking".
8-3. Some part of air conditioner does not operate.
8-3-1. Only indoor fan does not run.
• Check fan rotation.
Turn fan gently once or twice by
hand.
• Check fan casing
foreign matter on
inside.
Fan cannot
be turned.
Fan motor burnout
or foreign matter in
bearings.
Remove foreign
matter or repair.
Repair or replace.
• Measure resistance of indoor fan
motor winding.
OK
• Check fan motor capacitor.
8-3-2. Only outdoor fan does not run.
• Check fan rotation.
Turn fan gently once or twice by
hand.
• Check fan casing
foreign matter on
inside.
Fan cannot
be turned.
Fan motor burnout
or foreign matter in
bearings.
• Measure resistance of outdoor fan
motor winding.
OK
• Check fan motor capacitor.
30
Remove foreign
matter or repair.
Repair or replace.
8-3-3. Only compressor does not run.
Either overload relay or
internal protector is working.
(Either OLR or 49C)
• Check compressor motor
capacitor.
(C1)
YES
• Measure resistance of
compressor motor winding.
Temperature of compressor
is abnormally high.
YES
YES
Refrigerant gas shortage.
Recover refrigerant. (R407C)
NO
• Measure Power supply
voltage.
The voltage is too low.
No
Rotor may be locked up.
Evacuate the air conditioner.
YES
For compressor replacement
refer to "10-5. In case of
compressor malfunction".
CAUTION
Charge refrigerant in liquid
state.
(R407C)
In case of leakage, do not add refrigerant. The unit must be vacuumed
and recharged. This is because composition of refrigerant in the unit
has been changed due to leakage. See "9-6. In case refrigerant is leaking".
8-3-4. Only louver motor does not run.
• Measure resistance of louver motor
winding.
8-3-5. Function of outdoor fan speed control does not work properly.
• Check thermostat in outdoor unit.
(23S)
Refer to 7-3 "Outdoor Fan Speed Control."
31
8-4. Air conditioner operates, but abnormalities are observed.
8-4-1. Poor cooling.
• Check position of remote control unit.
• Cool air from air conditioner reaches
position directly.
YES
Change position of remote
control unit.
• Wide and narrow tubes between
indoor unit and outdoor unit are
insulated.
NO
Insulate both wide and narrow
tubes separately and then
tape together.
YES
• Measure temperature of suction and
discharge air of air conditioner.
Temperature
difference
is small.
Possibility of
gas shortage.
Temperature difference between
suction and discharge air is
large enough (approx. 10 deg. or more).
Recover
refrigerant.
Evacuate the
air conditioner.
Charge refrigerant
in liquid. (R407C)
Check for clogging of air filter.
Clean filter.
Air filter is clogged.
• Fan speed is set to LOW.
YES
Set fan speed to either
HIGH or MEDIUM.
Reduce cooling load or
replace the air conditioner
with larger capacity.
• Review cooling load estimate,
if performance of air conditioner is
normal.
8-4-2. Excessive cooling.
• Set temperature is suitable.
• Remote control unit is placed where
it can detect room temperature
properly.
Set temperature to higher
value using temperature
setting buttons of the remote
control unit.
NO
NO
Change position of remote
control unit.
32
8-5. If a sensor is defective.
8-5-1. Indoor coil temp. thermistor (TH1) is defective.
A. Open
When thermistor opens, the air conditioner will be in the following conditions as the controller tries to detect
extremely low indoor coil temperature.
In Cooling mode:
Function of freeze prevention continues to work. That is, the controller turns both
compressor and outdoor fan motor periodically ON and OFF for several minutes.
(Refer to "7-2. Freeze Prevention")
B. Short
When thermistor is short, the air conditioner will be in the following conditions as
the controller tries to detect extremely high indoor coil temperature.
In Cooling mode:
Function of freeze prevention will not work even when the frost builds up on indoor heat
exchanger coil
8-5-2. Room temp. thermistor (TH2) is defective.
A. Open
When thermistor opens, the air conditioner will be in the following conditions as the controller tries to detect
extremely low room temperature.
In Cooling mode:
The air conditioner soon stops and will not start again. (Thermo.OFF)
Neither outdoor fan nor compressor runs.
B. Short
When thermistor is short, the air conditioner will be in the following conditions as
the controller tries to detect extremely high room temperature.
In Cooling mode:
The air conditioner continues to operate (Thermo.ON). Both
the outdoor fan and compressor do not stop. As a result, the
room becomes too cold.
Temperature
sensor
Lead
wires
NOTE
Definition of Open or Short Circuit of Sensor (Thermistor)
Thermistor Structure
Open ... A lead wire is broken or disconnected or the circuit inside the temperature sensor is open .
Short ... The protective cover of a lead wire has been damaged, and the exposed wire is touching another metal
part, or both lead wires have become exposed and are touching each other. Alternatively, the circuit
inside the temperature sensor is closed.
33
9. REFRIGERANT R407C :
SPECIAL PRECAUTIONS WHEN SERVICING UNIT
9-1. Characteristics of new refrigerant R407C
9-1-1. What is new refrigerant R407C
R407C is a new refrigerant that contains three types of non-azeotropy-type mixed refrigerant which does
not adversely affect the Earth's ozone layer. Its refrigeration capacity and energy efficiency are about the
same level as the conventional refrigerant R22
9-1-2. Components (mixing proportions)
HFC32 (23%) / HFC125 (25%) / HFC134a (52%)
9-1-3. Characteristics
● Less toxic, more chemically stable refrigerant.
● Composition of refrigerant R407C changes whether it is in gaseous phase or liquid phase. Thus, when there is a
refrigerant leak the basic performance of the air conditioner may be degraded because of a change in
composition of the remaining refrigerant. Therefore, do not add new refrigerant. Instead, recover the
remaining refrigerant with the refrigerant recovery unit. Then, after evacuation, totally recharge the specified
amount of refrigerant with the new refrigerant at its normal mixed composition state (liquid phase).
● When refrigerant R407C is used, the composition will differ depending on whether it is in gaseous or liquid
phase, and the basic performance of the air conditioner will be degraded if it is charged while the refrigerant is in
gaseous state. Thus, always charge the refrigerant while it is in the liquid phase.
CAUTION
● Ether-type oil is used for the compressor oil for R407C-type units, which is
different from the mineral oil used for R22. Thus more attention to moisture
prevention and faster replacement work compared with conventional models are
required.
9-2. Checklist before servicing
● Tubing precautions
Refrigerant R407C is more easily affected by dust or moisture compared with R22, thus be sure to temporarily
cover the ends of the tubing with caps or tape prior to installation.
● No addition of compressor oil for R407C
No additional charge of compressor oil is permitted.
● No use of refrigerant other than R407C
Never use a refrigerant other than R407C.
● If refrigerant R407C is exposed to fire
Through welding, etc., toxic gas may be released when R407C refrigerant is exposed to fire. Therefore, be sure
to provide ample ventilation during installation work.
● Caution in case of R407C leak
Check for possible leak points with the special leak detector for R407C. If a leak occurs inside the room,
immediately provide thorough ventilation.
34
9-3. Tools specifically for R407C
● For servicing, use the following tools for R407C
Tool Distinction
Tool Name
• Gauge manifold
• Charging hose
• Gas leak detector
• Refrigerant cylinder
• Charging cylinder
Tools specifically for R407C
• Refrigerant recovery unit
• Vacuum pump with anti-reverse flow (✽1)
(Solenoid valve-installed type, which prevents oil from flowing back into the unit
when the power is off, is recommended.)
• Vacuum pump (✽2) ..... can be used if the following adapter is attached.
• Vacuum pump adapter (reverse-flow prevention adapter) (✽3).
(Solenoid valve-installed adapter attached to a conventional vacuum pump.)
• Electronic scale for charging refrigerant
• Flare tool
• Bender
Tools which can be commonly • Torque wrench
used for R22 and R407C
• Cutter, Reamer
• Welding machine, nitrogen gas cylinder
CAUTION
● The above tools specifically for R407C must not be used for R22. Doing so will
cause malfunction of the unit.
● For the above vacuum pump (✽1, ✽2) and vacuum pump adapter (✽3) , those for
R22-type units can be used for R407C-type. However, they must be used
exclusively for R407C and never alternately with R22.
9-4. For tubing installation procedures
● When the tubes are connected, always apply HAB oil on the flare portions to improve the sealing of
tubing.
The following is the HAB oil generally used:
Esso: ZERICE S32
NOTE
For details on tubing installation procedures, refer to the installation manuals attached to the indoor
unit and outdoor unit.
35
9-5. In case of compressor malfunction
CAUTION
● Should the compressor malfunction, be sure to replace compressor as quickly as
possible.
● Use only the tools indicated exclusively for R407C. ➞ See "9-3. Tools specifically
for R407C".
9-5-1.Procedure for replacing compressor
(1) Recovering refrigerant
• Any remaining refrigerant inside the unit should not be
released to the atmosphere, but recovered using the
refrigerant recovery unit for R407C.
(1). Recovering refrigerant
OK
• Do not reuse the recovered refrigerant, since will
contain impurities.
(2) Replacing compressor
(2). Replacing compressor
• Soon after removing pinched pipes of both discharge
and suction tubes of the new compressor, replace it
quickly.
OK
(3) Checking for sealing
(3). Checking for sealing
• Use nitrogen gas for the pressurized gas, and never
use a refrigerant other than R407C. Also do not use
oxygen or any flammable gas.
OK
(4) Evacuation
• Use a solenoid valve-installed vacuum pump so
that even if power is cut off in the middle of evacuation
of air due to a power interruption, the valve will
prevent the pump oil from flowing back.
• The equipment may be damaged if moisture remains
in the tubing, thus carry out the evacuation thoroughly.
• When using a vacuum pump with exhaust air volume
more than 25L/min. and ultimate vacuum pressure
rate of 0.05Torr:
Standard time of evacuation
Length of tubing Less than 10 m
Time
More than 10 min.
More than 10 m
More than 15 min.
36
(4). Evacuation
OK
(5). Recharging
(5) Recharging
Valve
• Be sure to charge the specified amount of
refrigerant in liquid state using the service port of
wide tube service valve. The proper amount is listed
on the unit's nameplate.
When the entire amount cannot be charged all at
once, charge gradually while operating the unit in
Cooling Operation.
CAUTION
Liquid
● Never charge a large amount
of liquid refrigerant at once
to the unit. This may cause
damage to the compressor.
• When charged with a refrigerant cylinder, use the
electronic scale for charging refrigerant. In this case, if
the volume of refrigerant in the cylinder becomes less
than 20% of the fully-charged amount, the composition
of the refrigerant starts to change. Thus, do not use
the refrigerant if the amount in the refrigerant
cylinder is less than 20%.
Single valve
Charge the liquid refrigerant
with the cylinder in the
up-side-down position.
Fig. 1
Valve
Also, charge the minimum necessary amount to the
cylinder before using it for charging the air
conditioning unit.
Example:
In case of charging refrigerant to a unit requiring
0.76Kg using a capacity of 10Kg-cylinder, the
minimum necessary amount for the cylinder is:
0.76 + 10 x 0.20 = 2.76Kg
Liquid
Single valve (with siphon tube)
Charge with the cylinder in the
normal position.
For the remaining refrigerant, refer to the
instructions of the refrigerant manufacturer.
Configurations and characteristics of cylinders
• If using a charging cylinder, transfer the specified
amount of liquid refrigerant from the refrigerant
cylinder to the charging cylinder.
Prepare an evacuated charging cylinder beforehand.
CAUTION
Fig. 2
NO!
● To prevent the composition
of R407C from changing,
never bleed the refrigerant
gas into the atmosphere
while transferring the
refrigerant. (Fig. 3)
Charging
cylinder
Do not use the refrigerant if the amount in the
charging cylinder is less than 20%.
Liquid
Open
Refrigerant
cylinder
Fig.3
37
9-6. In case refrigerant is leaking
CAUTION
● Never attempt to charge additional refrigerant when refrigerant has been leaking
from the unit. Follow the procedure described below to locate points of leaks and
carry out repairs, then recharge the refrigerant.
(1) Detecting Leaks
• Use the detector for R407C to locate refrigerant leak
points.
(2) Recovering refrigerant
(1). Detecting leaks
• Never release the gas to the atmosphere, recover
residual refrigerant using the refrigerant recovery unit
for R407C, instead.
OK
• Do not reuse the recovered refrigerant because its
composition will have been altered.
(2). Recovering refrigerant
(3) Welding leaking points
OK
• Confirm again that no residual refrigerant exists in the
unit before starting welding.
• Weld securely using flux and wax for R407C.
• Prevent oxide film from forming inside the tubes
utilizing substitution with nitrogen (N2) in the
refrigerant circuit of the unit. Leave ends of tubes open
during welding.
(4) Checking for sealing
(3). Welding leaking points
OK
(4). Checking for sealing
• Use nitrogen gas for the pressurized gas, and never
use a refrigerant other than R407C. Also do not use
oxygen or any flammable gas.
OK
(5) Evacuation
(5). Evacuation
• Use a solenoid valve-installed vacuum pump so
that even if power is cut off in the middle of evacuation
of air due to a power interruption, the valve will prevent
the pump oil from flowing back.
• The equipment may be damaged if moisture remains
in the tubing, thus carry out the evacuation thoroughly.
• When using a vacuum pump with exhaust air volume
more than 25L/min. and ultimate vacuum pressure rate
of 0.05Torr:
Standard time of evacuation
Length of tubing Less than 10 m
Time
More than 10 min.
More than 10 m
More than 15 min.
38
OK
(6). Recharging
(6) Recharging
Valve
• Be sure to charge the specified amount of
refrigerant in liquid state using the service port of
wide tube service valve. The proper amount is listed
on the unit's nameplate.
When the entire amount cannot be charged all at
once, charge gradually while operating the unit in
Cooling Operation.
CAUTION
● Never charge a large amount
of liquid refrigerant at once
to the unit. This may cause
damage to the compressor.
• When charged with a refrigerant cylinder, use the
electronic scale for charging refrigerant. In this case, if
the volume of refrigerant in the cylinder becomes less
than 20% of the fully-charged amount, the composition
of the refrigerant starts to change. Thus, do not use
the refrigerant if the amount in the refrigerant
cylinder is less than 20%.
Liquid
Single valve
Charge the liquid refrigerant
with the cylinder in the
up-side-down position.
Fig. 4
Valve
Also, charge the minimum necessary amount to the
cylinder before using it for charging the air
conditioning unit.
Example:
In case of charging refrigerant to a unit requiring
0.76Kg using a capacity of 10Kg-cylinder, the
minimum necessary amount for the cylinder is:
0.76 + 10 x 0.20 = 2.76Kg
Liquid
Single valve (with siphon tube)
Charge with the cylinder in the
normal position.
For the remaining refrigerant, refer to the instructions
of the refrigerant manufacturer.
Configurations and characteristics of cylinders
• If using a charging cylinder, transfer the specified
amount of liquid refrigerant from the refrigerant
cylinder to the charging cylinder.
NO!
Prepare an evacuated charging cylinder beforehand.
CAUTION
Fig. 5
● To prevent the composition
of R407C from changing,
never bleed the refrigerant
gas into the atmosphere
while transferring the
refrigerant. (Fig. 6)
Charging
cylinder
Liquid
Do not use the refrigerant if the amount in the
charging cylinder is less than 20%.
Open
Refrigerant
cylinder
Fig. 6
39
9-7. Charging additional refrigerant
9-7-1.When tubes are extended
• Observe the proper amount of refrigerant as stated in this service manual or the installation manual that came
with the indoor unit. Charge additional refrigerant in liquid state.
CAUTION
● Never charge additional refrigerant if refrigerant is leaking from the unit. Follow
instructions given in "9-6. In case refrigerant is leaking" and completely carry out
repairs. Only then should you recharge the refrigerant.
9-8. Retro-fitting existing systems
9-8-1 Use of existing units
• Never use new refrigerant R407C for existing units which use R22. This will cause the air conditioner to
operate improperly and may result in a hazardous condition.
9-8-2 Use of existing tubing
• If replacing an older unit that used refrigerant R22 with a R407C unit, do not use its existing tubing. Instead,
completely new tubing must be used.
40
10. CHECKING ELECTRICAL COMPONENTS
10-1.Measurement of Insulation
Resistance
Ground wire
● The insulation is in good condition if the resistance
exceeds 2MΩ.
Clip
10-1-1. Power Supply Wires
Probe
Clamp the grounding terminal of the power plug with a
lead clip of the insulation resistance tester and
measure the resistance by placing a probe on either of
the two power terminals. (Fig. 1)
Insulation
tester
Fig. 1
Terminal plate
Then, also measure the resistance between the
grounding and other power terminals. (Fig. 1)
10-1-2. Indoor Unit
Probe
Clamp an aluminum plate fin or copper tube with the
lead clip of the insulation resistance tester and
measure the resistance by placing a probe on each
terminal screw on the terminal plate. (Fig. 2)
Note that the ground line terminal should be skipped
for the check.
Clip
Copper
tube or
metallic part
10-1-3. Outdoor Unit
Insulation
tester
Fig. 2
Clamp an aluminum plate fin or copper tube with the
lead clip of the insulation resistance tester and
measure the resistance by placing a probe on each
terminal screw where power supply lines are
connected on the terminal plate. (Fig. 2)
Probe
Clip
10-1-4. Measurement of Insulation
Resistance for Electrical Parts
Copper
tube or
metallic part
Disconnect the lead wires of the desired electric part
from terminal plate, capacitor, etc. Similarly disconnect
the connector. Then measure the insulation resistance.
(Fiqs. 3 and 4)
Insulation
tester
Fig. 3
From fan motor,
compressor and
other parts
NOTE
Refer to Electric Wiring Diagram.
Metallic
part
If the probe cannot enter the poles because the hole is
too narrow then use a probe with a thinner pin.
Probe
Clip
Insulation
tester
45
Fig. 4
10-2.Checking Continuity of Fuse on
PCB Ass'y
Fuse
● Remove the PCB Ass’y from the electrical
component box. Then pull out the fuse from the PCB
Ass’y. (Fig. 5)
PCB Ass’y
● Check for continuity using a multimeter as shown in
Fig. 6.
Fig. 5
10-3.Checking Motor Capacitor
Remove the lead wires from the capacitor terminals,
and then place a probe on the capacitor terminals as
shown in Fig. 7. Observe the deflection of the pointer,
setting the resistance measuring range of the
multimeter to the maximum value.
Fuse
Fig. 6
The capacitor is “good” if the pointer bounces to a
great extent and then gradually returns to its original
position.
The range of deflection and deflection time differ
according to the capacity of the capacitor.
Multimeter
Compressor motor
capacitor
*1
Fan motor
capacitor
Fig. 7
NOTE
46
*1 Compressor motor capacitor is
provided only for 1-phase model.
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